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Product engineering simulation (CAE)

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Passive safety

Crashworthiness: All kinds of crash test procedures

Occupant protection:

  • Full restraint systems integration & validation
  • Whiplash simulation
Phase 1: Model construction
Subsystem tests for correlation
Whiplash test-CAE loop
  • FMVSS 201, Knee Mapping, OoP...

Pedestrian protection: Euro NCAP & ACEA test procedures

Particular studies: Bumper test, seatbelt anchorage, RCAR analysis

Road infrastructure:

  • Directive EN-1317 passenger cars, buses, trucks

Stiffness and fatigue analysis

Static stiffness

Dynamic stiffness

Fatigue analysis

  • Input forces from in-vehicle data acquisition
  • ADAMS (MultiBodySystem) model
  • Dang Van
  • Life prediction

Thermal analysis

  • Parcel shelf: Flexion at T=90º
  • Creep analysis
  • Interior trimming: Thermal expansion 90º
  • Thermal clearance analysis

NVH

Frequency and shape modes optimization

  • Body-in-White
  • Trimmed body

Correlation in prototype phases

  • Pretest: Definition of the wireframe
  • Simulation: Modal analysis

Calculation of the acoustic response

Analysis of sound pressure level:

  • Occupants position
  • Various car configurations
  • Various cases of excitations
  • Global noise simulation from test loads

Squeak & rattle

  • Important in the quality perception of the customer
  • Influence on tiredness and nervousness of drivers
  • Methodology developed for detecting possible problems by simulation

Squeal noise

  • On-vehicle brake squeal characerization in real conditions (speed, temperature, brake pressure)
Exterior noise recordings with microphones near the wheel
Interior noise recordings with microphones or Head-Acoustics
Vibration measurements on components
  • Squeal conditions
Main frequencies and noise amplitude
Squeal braking conditions: speed, temperature, brake pressure
  • CAE analysis
Diagnostic tool
Analyses based on test data
Countermeasures focused on disc and caliper
  • On-vehicle squeal validation

 Vehicle dynamics

IDIADA uses the latest CAE technology for simulating vehicle Ride, Handling and Durability performance. Many in-house techniques have been developed that allow integrated functional teams to work together. Typic simulation activities include:

Chassis design & development

Tuning support and target establishment

Active safety & chassis control system development

Suspension optimization studies

Ride comfort and durability analysis

Powertrain installation and driveline analysis

Tyre characterization & development

Fluid dynamics

External aerodynamics

  • LES turbulence model: detailed transient airflow
  • RANS turbulence model: efficient assessment
  • Styling phase: hat optimization
  • Engineering phase: body optimization

Aero-acoustics

Defrost systems

Heating, Ventilation & Air Conditioning (HVAC)

Underhood thermal management: Workflow

  • 1D simulation: cooling system definition
  • 3D simulation: airflow & part temperatures
 Automated methodology for model set-up (1 month - 1 week)
All physical phenomena considered:
(Heat exchangers / evaporators, condensers / compressor, fans / convection / conduction / radiation)

Engine simulation activities

  • 1D simulation with Gt-Power; AMESIM
Performance
Emissions
Combustion
Functional:
(Air and fuel consumption / pressures / temperatures)
  • 3D simulation with AVL fire
Intake and exhaust
In-cylinder flow
Injection
Combustion prediction
In-cylinder pressure and temperature
Emissions

Optimization

 Automated optimization

  • Solver independent optimizer
  • Combination of multiple load-cases
  • Library of optimization algorithms
  • Optimization variables:
Weld-spots position
Stamped parts thicknesses
Material definition
  • Stochastic analysis
  • In-house developed methodology